Install Instructions

Contents
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
⚠ DANGER
⚠ WARNING
⚠ CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but
not related to personal injury or property damage.
2
HAZARD DEFINITIONS ................................................... 2
PLEASE READ BEFORE PROCEEDING ................... 3-4
SAFETY INFORMATION ................................................. 4
THE COPPER-FIN -- HOW IT WORKS ....................... 5-7
RATINGS........................................................................ 8-9
1. DETERMINE UNIT LOCATION
Locating the Unit .............................................................. 10
Indoor Clearances from Combustible Construction ........ 10
Freeze Protection ........................................................ 11-12
Prevent Combustion Air Contamination ...................... 11-13
Combustion Air Options .............................................. 14-15
2. VENTING
General Venting Information ....................................... 16-17
Vent System Options
Conventional Negative Draft Venting .................... 18-21
Masonry Chimney Installation and Inspection ............ 19
Outdoor Installation Options .................................. 22-23
3. GAS CONNECTIONS
Connecting to Gas Supply ............................................... 24
Gas Pressure Test ........................................................... 24
Gas Piping ........................................................................ 24
Gas Connections / Gas Train and Controls ..................... 25
Combination Gas Valves .................................................. 26
Checking Gas Supply Pressure .................................. 26-27
Gas Manifold Pressure Adjustment ............................ 27-28
4. WATER CONNECTIONS
Inlet & Outlet Connections ............................................... 29
Relief Valve ...................................................................... 29
Heating Boiler Installations .......................................... 29-31
Low Temperature Return Water Systems ........................ 32
Primary/Secondary Piping of a Single Boiler .............. 33
Primary/Secondary Piping of Multiple Boilers ............ 34
Boiler w/Low Temperature Bypass Piping .................. 35
Primary/Secondary Piping with Buffer Tank ............... 36
Installation with a Chilled Water System .......................... 37
Typical Heating Boiler Installations .................................. 37
Boiler Flow Rate / Bypass Requirements ................... 37-38
Temperature/Pressure Gauge and Water Treatment ...... 38
5. ELECTRICAL CONNECTIONS
Connecting to Electrical Supply ....................................... 39
Line Voltage Connections ........................................... 40
EMS Connections ............................................................ 40
Terminal Strip Connection Options ............................. 40-41
Temperature Controls
Temperature Adjustment ............................................ 41
Outdoor Reset Option ................................................. 42
Temperature Control Sensors ............................... 43-44
Hot Surface Ignition System ............................................ 45
Operation and Diagnostic Lights ...................................... 46
6. STARTUP
Operating and Safety Instructions .................................... 47
Check Water Chemistry ................................................... 48
Freeze Protection (when used) ........................................ 48
Fill and Test Water System .............................................. 49
Purge Air from Water System .......................................... 49
Check for Gas Leaks / Thermostat Circuit(s) ................... 50
Check Vent and Air Piping ............................................... 50
Placing the Boiler in Operation ........................................ 50
7. DOMESTIC WATER HEATERS
General ............................................................................. 51
Water Velocity Control ..................................................... 51
Pipe Size Requirements
Typical Water Heater Piping w/ Storage Tank ........... 52
Single Water Heater Piping w/Two Storage Tanks ... 53
Multiple Water Heater Piping w/One Storage Tank ... 54
Multiple Water Heater Piping w/Multi. Storage Tanks . 55
Water Chemistry............................................................... 56
Circulating Pump/ Performance ....................................... 56
Heat Exchanger ............................................................... 57
Potable Hot Water Temperature Controls ........................ 57
Location of Cold Water Supply Piping Connections ........ 58
High Water Temperature Limit Control ............................ 59
Optional Relief Valve ........................................................ 59
Thermal Expansion and Cathodic Protection ................... 59
8. MAINTENANCE
Burner Flames .................................................................. 60
Burner Removal and Cleaning Procedures ................ 60-61
Adjusting Differential Air Pressure .............................. 61-62
Servicing a Hot Surface Igniter / Ignition Module ............ 63
Sequence of Operation Overview ............................... 63-64
9. GLOSSARY & NOTES .......................................... 65-67
10. DIAGRAMS ........................................................... 68-71
Revision Notes .................................................. Back Cover